Substructure and crawl space enclosure for factory constructed buildings

ABSTRACT

A building support system assembled on a ground interface such as, but not limited to, an in-situ poured continuous concrete grade beam, using a plurality of adjustable stanchions and pre-cast cementitious panels. The fabricated stanchions attach to the building perimeter structural element and to said ground interface. Pre-cast cementitious panels with shear capacity attach to the stanchions, enclose the crawl space, retain soil, provide weather protection and with all components acting together transfer gravity, wind, snow and seismic forces from said building to said ground interface. The system has provisions for crawl space ventilation.

REFERENCES CITED

U.S. PATENT DOCUMENTS 3,831,329 8/1974 Lear 52/126 4,458,463 7/1984Behrend 52/295 4,680,904 7/1987 Stoeker 52/169.12 4,738,061 4/1988Herndon 52/126.6 5,664,377 9/1997 Angelo and Kambozia 52/295 6,076,3206/2000 Butler 52/294

BACKGROUND OF THE INVENTION

The purpose of the invention is to facilitate a new and improvedapparatus and method for installing factory constructed buildings thatrequire perimeter support. These structures include factory builthousing, commercial modular buildings and some manufactured homes.Conventionally said buildings are set on masonry block or stem wallfoundations, which are often faulty dimensionally and out of level.These faults result in unsatisfactory results such as out of levelfloors, out of plumb walls, doors, and windows. Installation is oftenhazardous using either costly cranes or labor intensive sliding,adjusting and attaching. Utility connections are made working throughtiny/access doors and working around internal walls with limitedopenings, slowing productivity. Other inventors have developed apparatusand methodology to alleviate some of these problems. Previous inventionseither do not have the structural capacity to support buildings for therequired gravity, wind, snow, and seismic loads and are therefore nomore than skirting. Others require temporary blocking and leveling whilethe building is in a precarious state. Leveling is required beforeembedding these apparatus in concrete or other cementitious materials.Many have inadequately protected metal components in close proximity toearth, which promotes corrosion.

SUMMARY OF THE INVENTION AND METHOD OF USE

The invention requires the installation of a ground interface or“foundation”, such as a continuous reinforced concrete grade beam whichis either cast in-situ or pre-cast, or isolated concrete footings,either cast in-situ or pre-cast, or a treated wood foundation in agravel bed. Said ground interface is engineered to transmit gravity,wind, snow, and seismic forces to the earth and below frost level ifnecessary. Said ground interface is laid so that the top surface islevel with the surrounding grade. If the building modules are to be setin a pit, with the crawl space below grade, then a ramp must be gradedto facilitate installation. Said building modules can then be maneuveredvia truck close to their final location on the temporary running gearused for overland transportation to the site. Said temporary runninggear is installed at the factory where said building modules are built.Said building modules can be maneuvered into their exact locations oversaid ground interface using commercially available rollers and jacks.This process is not dangerous as said modules still possess their wheelsand hitch's or carriers, which prevent falling. A plurality of supportstanchions, one of the components of the invention, are then positionedand attached to the perimeter structural members of said buildingmodules using nut and bolt fasteners. Said stanchions are attached tosaid ground interface with anchoring bolts. Said building modules arethen lifted off said wheels and hitches or carriers by said stanchion'sadjustable screw. Said temporary wheels and axles or carrier can then besafely removed. Said stanchions allow for fine leveling, to 1/16^(th) ofan inch. Said building's utilities can be easily connected to theunderside of said building modules as the perimeter of said crawl spaceis wide open. The pre-cast cementitous panels, which are a component ofthe invention, are then attached to said stanchions via commerciallyavailable panel adhesive and screw fasteners. Said metal stanchions andsaid pre-cast cementitious panels once attached together constitute thecomplete invention and became a single structural entity with greatercapacity to transmit gravity, wind, snow and seismic forces to saidground interface than the components can independently. Said inventionis labor saving, adjustable, and extremely strong. Said invention alsoallows for future re-leveling in the event of differential settlement.Ventilation for said crawl space is accomplished by a screened gapbetween said pre-cast cementitious panel and the underside of saidbuilding modules. Said gap may be hidden by said building's stuccoscreed or exterior sheathing. Said pre-cast cementitious panels can bebackfilled with earth so that the floor level inside said building canbe closer to the outside grade.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the fabricated metal stanchion andpre-cast cementitious panel used in the perimeter application of thepreferred embodiment depicted in bold between the factory constructedbuilding and the ground interface.

FIG. 2 is a front elevation view of FIG. 1.

FIG. 3 is a front elevation view of the structural connection betweensaid pre-cast cementitious panels where said fabricated metal stanchionis not required.

FIG. 4 is a cross section elevation view of FIG. 1.

FIG. 5 is a cross section plan view of FIG. 1.

FIG. 6 is a cross section elevation view of FIG. 3.

FIG. 7 is a cross section plan view of FIG. 3.

FIG. 8 is a front elevation view of said fabricated metal stanchion asused between factory constructed building modules.

FIG. 9 is a plan view of the location of said fabricated metal stanchionin FIG. 8 on the ground interface.

FIG. 10 is a plan view of the alternate location of said fabricatedmetal stanchion in FIG. 8 on the ground interface.

FIG. 11 is a side elevation view of FIG. 8.

FIG. 12 is a cross-section plan view of FIG. 11.

DESCRIPTION OF THE PREFERRED EMBODIMENT

There are four main components that constitute the substructure andcrawl space enclosure for factory constructed buildings. Two of saidmain components of the preferred embodiment of the invention are locatedin FIGS. 1, 2, and 4, between 6 and 11. The first main component 2 is apre-cast cementitious panel. The second main component is a fabricatedmetal stanchion assembly composed of 1, 7, 12, 13, 15, 16, 17, 18 and21. The third main component, a splicing assembly, FIGS. 3, 6 and 7,which is composed of structural metal “T” 1 and metal angle 19 used tostructurally connect pre-cast cementitious panels 2 together where afabricated metal stanchion is not needed. The fourth main component is afabricated metal stanchion assembly, FIGS. 8 and 11, composed of 1, 7,12, 13, 15, 16, 17, and 18. Said stanchion is used between factoryconstructed building modules for support where pre-cast cementatouspanels 2 are not needed.

Item 6 is the ground interface to which said invention is mounted. Saidground interface 6 as illustrated is embodied as a concrete grade beamwith steel reinforcing bars 5. The size of said grade beam 6 and amountsof said steel reinforcing 5 is dictated by the individual soil, gravity,wind, snow, and seismic conditions for the individual location wheresaid invention is used and varies on each installation. Said groundinterface 6 can have other embodiments such as individual pre-castconcrete footings or treated lumber set in a gravel bed. Said inventionis mounted to the ground interface by anchoring bolts 4. Said inventionsupports a factory built building structure by the perimeter structuralmember 11, which in the illustrated embodiment is a steel “I” beam. Saidbuildings may have other embodiments for said perimeter structuralcomponents 11 such as a steel “C” channel, laminated wood beams or rimjoists. If the main structural member 11 is another embodiment thenstructural metal “T” 1 will be modified to attach to said embodiment.Said fabricated stanchions attach to said building structural member 11at structural metal “T” 1 by nut and bolt fasteners 8. Said building'sfloor joists 10 and structural stiffeners 14, are not part of theinvention but are identified for understanding.

The first major component, pre-cast cementitous panel 2 in thisembodiment is cast two inches thick, is approximately two feet tall,four feet long and may or may not have a tongue and groove on the ends.

The second major component, a stanchion assembly is fabricated from 1,7, 12, 13, 15, 16, 17, 18 and 21, FIG. 1, 2, and 4. In the preferredembodiment said items are welded together starting at the top with thestructural “T” 1 which mates flange to flange with the “I” beamperimeter structural member 11 of the factory constructed buildingmodule,with nut and bolt fasteners 8. Structural metal “T”1 has holesfor screw fasteners 3 to connect pre-cast cementitious panels 2. Between1 and 2, commercially available panel adhesive 9 is applied duringassembly. Welded to structural metal “T”1 is a round structural metaltube 15 designed to have a metal all-thread rod 12 inserted into it witha small clearance. The relationship of these items is shown in FIG. 5, across sectional illustration of structural metal “T”1 with attachedparts. Metal all-thread rod 12 is designed to turn inside the roundstructural metal tube 15 when rotated. A threaded nut 17 welded to themetal all-thread rod 12 is used to facilitate rotating with a wrench.The lower end of metal all-thread rod 12 is threaded into a largethreaded nut 18, as shown in plan view FIG. 12, which is welded into arectangular structural metal tube 7. Metal all-thread rod 12 has athreaded nut 13, threaded onto it between threaded nut 17 and threadednut 18 to be used as a lock nut against said threaded nut 18. Structuralmetal tube 7 is welded to the metal base plate 16. The metal base platecontains holes which allow the anchoring bolts 4 to be inserted into theground interface 6. See FIG. 2, the base plate 16, also has metal fins21 welded to it for the commercially available panel adhesive 9 andscrew fasteners 3 to attach said pre-cast cementitious panel 2 to thelower part of the stanchion.

The third main component, a splicing assembly, FIGS. 3, 6 and 7,composed of structural metal “T” 1 and metal angle 19 used tostructurally connect pre-cast cementitious panels 2 together where afabricated metal stanchion is not needed. Structural “T” shape 1 matesflange to flange with the “I” beam perimeter structural member 11 of thefactory constructed building module with nut and bolt fasteners 8.Structural metal “T”1 has holes for screw fasteners 3 to connect topre-cast cementitious panels 2. Between 1 and 2, commercially availablepanel adhesive 9 is applied during assembly. On one side metal angle 19has holes to attach screw fasteners 3 to pre-cast cementitious panel 2.Between 19 and 2, commercially available panel adhesive 9 is appliedduring assembly. On the other leg the metal angle 19 has holes foranchoring bolts 4 to mount to the ground interface 6.

The fourth major component, a stanchion assembly composed of 1, 7, 12,13, 15, 16, 17, and 18 used between building modules, FIGS. 8 and 11.Said stanchion is constructed the same as the second major component butlacks metal fins 21 which are unnecessary as no pre-cast cementitiouspanels 2 are attached. Since said stanchions are supporting two adjacentbuilding modules the ground interface 6 is widened and said stanchionssupport both modules on one ground interface 6, FIGS. 9 and 10.

Ventilation of the crawl space is accommodated by a screened gap 23,FIG. 4 and 6, between the building sheathing, said pre-cast cementitiouspanel 2 and modular building perimeter element 11.

Joints between said pre-cast cementitious panels 2 are caulked. Aconcrete screed 26 is poured between said pre-cast cementitious panel 2and the ground interface 6 to seal the area and imbed any of the exposedportion of the stanchion in concrete, FIG. 4 and 6. Commerciallyavailable waterproofing 25 is applied to the outside of the pre-castcementitous panels 2.

Calculations for the required gravity, wind, snow, and seismic loads andbuilding geometry dictate the placement and number of requiredstanchions assemblies, splicing assemblies and pre-cast cementitiouspanels 2.

Method of Use

The ground interface, which will serve as the building foundation, isinstalled by commonly practiced means, and if site cast cementitiousin-situ, allowed to cure. The first building module is then maneuveredinto position by delivery truck or commonly used jacks and rollers. Theheight of the stanchions is adjusted down by rotating the all-threadrod, using a wrench on the attached nut, to the correct height to fitunder the building modules as they sit on their wheels and hitches. Thestanchions are attached to the perimeter structural member of thebuilding modules by nut and bolt fasteners. When all stanchions areinstalled the stanchions are adjusted to the desired building height.The anchoring bolts are installed into the ground interface, thebuilding module is leveled and the locknuts are tightened. If there aresubsequent building modules, they are moved in adjacent to the lastmodule and the process is repeated. When all modules are set, it is safeto remove all running gear, attach the modules as called for by themanufacturer, and connect the utilities and install insulation. Afterall work is completed under the building modules the cementitiouspre-cast panels are attached to the stanchions and splices around saidbuilding perimeter with adhesive and screw fasteners. A screen isinstalled in the vent area above said pre-cast cementitious panel andthe perimeter structural member of said building modules. The jointsbetween said pre-cast cementitious panels are caulked. A concrete screedis poured between said pre-cast cementitious panel and the groundinterface to seal the area and imbed any of the exposed portion of thestanchion in concrete. Waterproofing is applied to the outside of thepre-cast cementitious panels, across said concrete cant and onto theground interface. Said pre-cast cementitious panels can be backfilled ifdesired. No metal is in direct contact with earth, the stanchions can begalvanized to prevent corrosion.

SCOPE OF INVENTION

The invention can be used as a support for all factory built buildingmodules including modular homes, manufactured homes that requireperimeter blocking and commercial modular buildings. Unlike masonryblock or concrete stem wall foundations said invention eliminates timeconsuming and laborious work, there is no possibility of directional orleveling inaccuracy. Unlike other substructure systems there is nodanger while working under temporarily supported units before thestructure is on the foundation. Labor necessary to install is minimal.There is no metal that comes in contact or proximity of the earth, andin the event of differential settlement the building can be re-leveled.The unique combination of steel stanchions and pre-cast cementitiouspanels, working as a single structural entity, is extremely effective attransferring gravity, wind, snow and seismic loads to the groundinterface. The system can be used under extreme conditions and tosupport multi-story buildings. The invention can also be used as areplacement foundation for deficient buildings.

Inventors have disclosed inventions that address some but not all of theproperties of this disclosed invention. Research yielded many inventionswhich used panelized systems designed to enclose the crawl spaces ofmanufactured buildings and retain soil when backfilled, but do notsupport the structure. These structures are all supported by separatesystems of piers located inboard of the structures perimeter. Theability of the currently disclosed invention to support structures andsimultaneously enclose the crawl space makes this invention differentand superior to the many patents which disclose non-load bearingskirting systems. Donald Lear, U.S. Pat. No. 3,831,329 disclosed aninvention which supports a building floor structure using adjustablesteel piers. The Lear patent addresses ease of construction and theability to re-level a structure after soil heaving or failure but doesnot address transferring any forces to the ground. It is obviouslyintended to transfer gravity and perhaps snow loads, but there is littleapparent shear capacity in the system for wind or seismic loads and noclaims are made to enclose the crawl space with the invention. BehrendU.S. Pat. No. 4,458,463 disclosed a system which allows for the levelingof a structure using a steel pier mounted on anchor bolts set inconcrete. The anchor bolts are deficient in resisting lateral forces andthe invention stresses re-adjustability in conditions of shifting soilrather than stability and force resistance. Current building codes willnot allow for construction in such conditions. The invention does notinclude a crawl space enclosure. Stoecker U.S. Pat. No. 4,680,904disclosed an adjustable perimeter enclosure designed to separate theunderside of a trailer from the atmosphere. The invention appearssimilar to said disclosed invention in its embodiment but does not claimany of the same capabilities. It will not support the structure or allowbackfilling to grade. The principle claim of the invention is of askirting system which is easily relocated. Hermdon U.S. Pat. No.4,738,061 invented an adjustable building support system withbackfillable skirting. The invention has the same goals as saiddisclosed invention but is designed to support manufactured homes whichare supported by a steel frame set in from the perimeter of thestructure. Hermdons invention is not suitable for perimeter supportedfactory built structures. The load bearing components were notintegrated with the soil retaining components and therefore thefiberglass skirting does not contribute any lateral structural strengthto the structure. The invention is designed to meet federal codes butnot the current stricter local codes. The lack of lateral strength willcause the system to be deficient in carrying wind and seismic forces tothe ground interface. Angelo and Nareghi U.S. Pat. No. 5,664,377disclosed a support system for manufactured or modular homes. The Angeloand Nareghi invention does not possess all the advantages of the saiddisclosed invention. The system requires potentially hazardous and timeconsuming pre-leveling on temporary blocking. The stanchions are hungfrom the structure and geo-textile bags are attached to the stanchionsand pumped full of concrete while the building is temporarily blocked inplace. The footing is cast on the surface of the earth and does notextend below the frost level in cold climates. The patent does not teacha soil retaining system for the crawl space in below groundinstallations. Butler U.S. Pat. No. 6,076,320 disclosed a system usingvertical corrugated sheets for support and retaining earth. The Butlersystem requires hazardous pre-leveling on temporary blocking. Laborintensive trenches must be dug under the blocked-up building modules.The system is hung off the building structure and is cast in concrete.The corrugated sheets are in close proximity to the earth and even witha coating can be subject to corrosion when backfilled. The equipmentused for temporary blocking must be dismantled under the structure andbe hauled out through a small access door. Although the Butler inventionpossesses the strength necessary to transfer gravity, snow, wind andseismic loads to the ground, as required by current building codes, itis very labor intensive to install in comparison to the currentlydisclosed invention and is potentially subject to corrosion whenbackfilled. None of the prior art integrate the support and enclosurepanels structurally to form a system with the adjustability, ease ofinstallation, safety, ventilation and structural capacity of thecurrently disclosed invention.

1. A factory built building substructure with crawl space enclosure anda method of installation comprising: a. A plurality of metal stanchionshaving upper and lower ends connected by a metal all-thread rod. b. Anadaptation at said upper end to engage the perimeter structural memberof said factory built buildings and a metal pipe to engage saidall-thread rod c. An adaptation at said lower end to engage a groundinterface using a flat plate with anchoring bolts and a rectangularsteel tube with contained nut to engage said all-thread rod. d. A nut isattached to said all-thread rod as a means to rotate said all-thread rodwhich changes the height of said stanchion. e. Flat surfaces on saidupper and lower ends of said stanchions to adhere and fasten pre-castcemetitious panels as a means of transferring forces between componentsand enclosing said crawl space. f. A screened gap between the top ofsaid pre-cast cementatious panels and said perimeter structural memberof said factory built building as a means of ventilation. g. A metalangle and a structural metal “T” shape to attache said pre-castcemetitious panels where no stanchions are necessary.
 2. A substructureand crawl space enclosure according to claim 1 wherein the number andplacement of said metal stanchions and said pre-cast cementitious panelsis determined by each individual said factory built building's mass,configuration and the natural forces it is subjected to.
 3. Asubstructure and crawl space enclosure according to claim 1 thattransfers gravity, wind, snow and seismic loads of said factory builtbuilding to said ground interface by mean of a combination of saidstanchions and said attached per-cast cementitious panels as astructurally unified assembly more effectively then said structuralcomponents working independently.
 4. A method for installing saidfactory built buildings whereas: Said ground interface is constructed inadvance. A plurality of said factory built building modules aremaneuvered into position by delivery truck and commercially availablejacks and rollers. A plurality of said stanchions are attached andadjusted to bear the load of said factory built building modules safelybefore work takes place underneath. Said factory built building modulesare attached together according to the manufacturers instructions.Utilities are connected. Said pre-cast cementitious panels are adhered,fastened, waterproofed and backfilled.
 5. A method according to claim 4wherein a structurally unified assembly is the result.
 6. A methodaccording to claim 4 wherein a crane to lift said building modules intoplace is unnecessary for one story installations.
 7. A substructure andcrawl space enclosure according to claim 1 that has no metal componentsthat are in direct contact with earth thus avoiding corrosion.